Methods for biological processing of hydrocarbon-containing substances and system for realization thereof

ABSTRACT

The present disclosure is related to systems and methods for the biological processing of hydrocarbon-containing substances. In particular embodiments, the systems and methods herein relate to pre-digestion of hydrocarbon containing substances and further processing of the same to produce hydrocarbon fuels, fertilizer, and other products.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of, and claims the benefit of andpriority to, U.S. Non-Provisional patent application Ser. No.16/090,983, filed Oct. 3, 2018, and entitled “METHODS FOR BIOLOGICALPROCESSING OF HYDROCARBON-CONTAINING SUBSTANCES AND SYSTEM FORREALIZATION THEREOF,” which is a national stage entry of InternationalPatent App. No. PCT/US18/50031, filed on Sep. 7, 2018, and entitled“METHODS FOR BIOLOGICAL PROCESSING OF HYDROCARBON-CONTAINING SUBSTANCESAND SYSTEM FOR REALIZATION THEREOF”, which claims the benefit of andpriority under 35 U.S.C. § 119 to U.S. Provisional Patent ApplicationNo. 62/555,410, filed Sep. 7, 2017, and entitled “Method for BiologicalProcessing of Hydrocarbon-Containing Substances and System forRealization Thereof,” and U.S. Provisional Patent Application No.62/568,874, filed Oct. 6, 2017, and entitled “Systems and Methods forBiological Processing of Hydrocarbon-Containing Substances,” thedisclosures of which are incorporated by reference in their entiretiesas if the same were fully set forth herein.

TECHNICAL FIELD

The present disclosure relates generally to systems and methods for thebiological processing of hydrocarbon-containing substances.

BACKGROUND

With a growing population, it is predicted that energy consumption willcontinue to increase, resulting in the possibility of a shortage innatural resources. With this growing demand, versatile sources of energywith a low impact on the environment are needed. Advances in science andtechnology have enabled the exploration of alternative sources of energyproduction, such as the use of hydrocarbons. However, there areincreasing concerns that hydrocarbon resources may be depleted and thedevelopment of a more efficient recovery process and/or use of availablehydrocarbons is needed.

Additionally, a relatively high rate of waste production is emerging andwaste management is increasingly becoming a concern as improvements intechnology and recycling systems have not been developed to sufficientlycounteract the increases in waste production. Further, if improperlytreated, recycling of waste can lead to the production of a sludgecontaining highly toxic materials such as heavy metals and industrialsolvents.

Therefore, there is a long-felt but unresolved need for a system ormethod that converts hydrocarbon-containing substances to various typesof sustainable fuels, gases, and fertilizer, thus creating valuableproducts while improving and protecting the environment.

BRIEF SUMMARY OF THE DISCLOSURE

Briefly described, and according to one embodiment, aspects of thepresent disclosure generally relate to systems and methods for thebiological processing of hydrocarbon-containing substances.

According to a first aspect, a method for transforming waste intohydrocarbon fuels including: A) creating a predigested coal slurry bymixing coal fines, water, urea, a culture of Bacillus Firmus bacteriaand a dispersant agent in a pre-digestion tank; B) transferring thepredigested coal slurry to a vacuum digester, including a first burnerlance; C) heating the predigested coal slurry via the first burnerlance, producing combustion gases and first naphtha vapors; D)condensing and storing the first naphtha vapors; E) heating thecombustion gases via a second burner lance in an atmospheric digester,producing second naphtha vapors; and F) condensing and storing thesecond naphtha vapors.

According to a second aspect, the method of the first aspect or anyother aspect, wherein: A) heating the predigested coal slurry furtherproduces first creosote solids; and B) the method further includestransporting the first creosote solids to a chemical tote bin.

According to a third aspect, the method of the second aspect or anyother aspect, wherein the method further includes creating a creosotemixture by mixing the first creosote with water, bacteria, and urea.

According to a fourth aspect, the method of the third aspect or anyother aspect, wherein the method further include stirring the creosotemixture at regular intervals for at least a week to produce fertilizer.

According to a fifth aspect, the method of the fourth aspect or anyother aspect, wherein: A) the combustion gases are first combustiongases; B) heating the first combustion gases via the second burner lanceproduces second combustion gases; and C) the method further includestransporting the second combustion gases to at least one scrubber tankfor scrubbing the second combustion gases.

According to a sixth aspect, the method of the fifth aspect or any otheraspect, wherein: A) the at least one scrubber tank produces scrubberwater including electrolytes; and B) the method further includes addingthe scrubber water to the creosote mixture.

According to a seventh aspect, the method of the sixth aspect or anyother aspect, wherein the at least one scrubber tank is operativelyconnected to at least one ejector for scrubbing the second combustiongases.

According to an eighth aspect, the method of the seventh aspect or anyother aspect, wherein the pre-digestion tank is about 500 bbls capacityand includes fiberglass.

According to ninth aspect, the method of the eighth aspect or any otheraspect, wherein the dispersant is liquid dish soap or a chemicalequivalent.

According to a tenth aspect, the method of the ninth aspect or any otheraspect, wherein the predigested coal slurry has a pH of about 7-9.

According to an eleventh aspect, the method of the tenth aspect or anyother aspect, wherein the predigested coal slurry includes about 0.66%by weight urea.

According to a twelfth aspect, the method of the eleventh aspect or anyother aspect, wherein the predigested coal slurry includes about 3-6% byweight liquid dish soap.

According to a thirteenth aspect, the method of the twelfth aspect orany other aspect, wherein the predigested coal slurry includes about150-300 ml of 15-15-15 plant fertilizer.

According to a fourteenth aspect, the method of the thirteenth aspect orany other aspect, wherein the method further include transferring thepredigested coal slurry to a day tank.

According to a fifteenth aspect, the method of the fourteenth aspect orany other aspect, wherein the method further includes adding one or moreof the group including coal fines, wood chips, and recycled carpet, tothe predigested coal slurry in the day tank.

According to a sixteenth aspect, the method of the fifteenth aspect orany other aspect, wherein the method further includes adding 1-3 lbs ofurea and 30-60 gallons of water to the predigested coal slurry in theday tank.

According to a seventeenth aspect, the method of the sixteenth aspect orany other aspect, wherein the method further includes pumping ordraining the predigested coal slurry from the day tank to the vacuumdigester.

According to an eighteenth aspect, a system for transforming waste intohydrocarbon fuels including: A) a pre-digestion tank for creating apredigested coal slurry by mixing coal fines, water, urea, a culture ofBacillus Firmus bacteria and a dispersant agent; B) a vacuum digesteroperatively connected to the pre-digestion tank and including a burnerlance, the vacuum digester for heating the predigested coal slurry viathe first burner lance, producing combustion gases and first naphthavapors; C) a double-pipe heat exchanger fluidly connected to the vacuumdigester for condensing the first naphtha vapors; D) a first naphthatank fluidly connected to the double-pipe heat exchanger for storing thecondensed first naphtha vapors; E) a second burner lance in anatmospheric digester fluidly connected to the vacuum digester, forproducing second naphtha vapors from the combustion gases; F) acondenser fluidly connected to the atmospheric digester for condensingthe second naphtha vapors; and G) a second naphtha tank for storing thecondensed second naphtha vapors.

According to a nineteenth aspect, the system of the eighteenth aspect orany other aspect, wherein the system further includes a chemical totebin for storing creosote solids produced by the vacuum digester or theatmospheric digester.

According to a twentieth aspect, the system of the nineteenth aspect orany other aspect, wherein the system further includes at least onescrubber tank for scrubbing the combustion gases.

According to a twenty-first aspect, the system of the twentieth aspector any other aspect, wherein the at least one scrubber tank isoperatively connected to at least one ejector for scrubbing the secondcombustion gases.

According to a twenty-second aspect, the system of the twenty-firstaspect or any other aspect, wherein the pre-digestion tank is about 500bbls capacity and includes fiberglass.

According to a twenty-third aspect, the system of the twenty-secondaspect or any other aspect, wherein the system further includes at leastone column operatively connected to the vacuum digester for transportingthe second naphtha vapors to the condenser.

These and other aspects, features, and benefits of the claimedinvention(s) will become apparent from the following detailed writtendescription of the embodiments and aspects taken in conjunction with thefollowing drawings, although variations and modifications thereto may beeffected without departing from the spirit and scope of the novelconcepts of the disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate one or more embodiments and/oraspects of the disclosure and, together with the written description,serve to explain the principles of the disclosure. Wherever possible,the same reference numbers are used throughout the drawings to refer tothe same or like elements of an embodiment, and wherein:

FIG. 1 illustrates an exemplary, high-level overview process, accordingto one embodiment of the present disclosure.

FIG. 2 is a flowchart of a pre-digestion process, according to oneembodiment of the present disclosure.

FIG. 3 is a flowchart of a storage and purification of naphtha vaporsprocess, according to one embodiment of the present disclosure.

FIG. 4 is a flowchart of an exemplary process for convertinghydrocarbons to fertilizer, according to one embodiment of the presentdisclosure.

FIG. 5 illustrates various exemplary system components, according to oneembodiment of the present disclosure.

FIG. 6 illustrates exemplary system components, according to oneembodiment of the present disclosure.

FIG. 7 illustrates exemplary system components, according to oneembodiment of the present disclosure.

FIG. 8 illustrates an exemplary chemical tote bin component, accordingto one embodiment of the present disclosure.

DETAILED DESCRIPTION

For the purpose of promoting an understanding of the principles of thepresent disclosure, reference will now be made to the embodimentsillustrated in the drawings and specific language will be used todescribe the same. It will, nevertheless, be understood that nolimitation of the scope of the disclosure is thereby intended; anyalterations and further modifications of the described or illustratedembodiments, and any further applications of the principles of thedisclosure as illustrated therein are contemplated as would normallyoccur to one skilled in the art to which the disclosure relates. Alllimitations of scope should be determined in accordance with and asexpressed in the claims.

Whether a term is capitalized is not considered definitive or limitingof the meaning of a term. As used in this document, a capitalized termshall have the same meaning as an uncapitalized term, unless the contextof the usage specifically indicates that a more restrictive meaning forthe capitalized term is intended. However, the capitalization or lackthereof within the remainder of this document is not intended to benecessarily limiting unless the context clearly indicates that suchlimitation is intended.

Also, as used in the specification including the appended claims, thesingular forms “a,” “an,” and “the” include the plural, and reference toa particular numerical value includes at least that particular value,unless the context clearly dictates otherwise. Ranges may be expressedherein as from “about” or “approximately” one particular value and/or to“about” or “approximately” another particular value. When such a rangeis expressed, another embodiment includes from the one particular valueand/or to the other particular value. Similarly, when values areexpressed as approximations, by use of the antecedent “about,” it willbe understood that the particular value forms another embodiment.

As will be understood by one having ordinary skill in the art, the stepsand processes described herein may operate concurrently andcontinuously, are generally asynchronous and independent, and are notnecessarily performed in the order discussed.

These and other aspects, features, and benefits of the claimeddisclosure(s) will become apparent from the following detailed writtendescription of the embodiments and aspects taken in conjunction with thefollowing drawings, although variations and modifications thereto may beeffected without departing from the spirit and scope of the novelconcepts of the disclosure.

Overview

An exemplary process begins with the pre-treatment of thehydrocarbon-containing substances. The hydrocarbon-containing substancesmay undergo hydrolysis and acidification in order to reduce largemolecules and form organic acids. In various embodiments, a workingmixture of a bacteria, urea, and water may be used break down (e.g.“loosen”) the hydrocarbons.

Generally, the process continues with converting components of thehydrocarbon containing liquid mixture into gases and vapors. Thisprocess may take place in anaerobic digesters or the like and may run atany suitable temperature for the conversion of hydrocarbon containingliquids to various types of combustion gases. During this process, somemolecules such as water, amines, and carbonates may resist breakdown andmay be drained for various additional uses. In some embodiments,carbonaceous chemical creosote may be collected and converted tofertilizer (as discussed herein).

In various embodiments, the disclosed system includes: a reservoir(e.g., a pre-digestion tank) for preparing a working mixture andbiodegradation of hydrocarbon-containing substances; various tankcollectors for viscous substances; pumps; various digesters; heatingreservoir; collectors for separated combustible fractions ofhydrocarbons; pipelines for supplying and removing combustion products;collectors for residual materials; gas condensers; gas compressors andvarious tanks for purifying combustion products.

In various embodiments, the system may purify the combustion gases by aseries of compressors and tanks. This process may continue with the useof gas scrubber tanks, or the like, that are efficiently and effectivelydesigned to remove gas pollutants (e.g. ammonia, chlorine or sulfurcompounds). In some embodiments, the gas scrubber tanks filled withwater function by dissolving and/or absorbing the pollutants into thescrubbing liquid. In various embodiments, the scrubber tanks incorporatea recycle drum and pump to ensure removal of pollutants is efficiencyachieved. Generally, gases may enter the scrubber tanks where itcontacts the scrubbing fluid and captures the pollutants resulting withan end-product of purified water loaded with electrolytes. In variousembodiments, the water loaded with electrolytes along with creosote, maybe stored in chemical tote bins to which the above mentioned workingmixture may be added to produce a fertilizer solution.

As will be understood, this disclosure plays no limitations on the typesof tanks (e.g. surge tanks manufactured by Global Industrial, of PortWashington, N.Y.), digesters (e.g. vacuum digesters manufactured byAlibaba, of China) compressors (e.g. gas compressors manufactured byExterran, of Houston, Tex.) and pumps (e.g. supply pump manufactured byPump Supply Inc., of Elgin, Ill.) used (and further discussed below).

Exemplary applications of the disclosed system and method generallyinclude the use of the end-products (e.g. fertilizer, gases, andvapors). In various embodiments, markets for the end-products mayinclude industries such as oil refineries (e.g. the use of naphthastreams due to low sulfur content) and agriculture (e.g. the use offertilizer). As will occur to one having ordinary skill in the art, thisdisclosure places no limitations on the applications for the disclosedproducts of the systems and methods described herein.

Exemplary Embodiments

Referring now to the figures, for the purposes of example andexplanation of the fundamental processes and components of the disclosedsystems and methods, reference is made to FIG. 1 , which illustrates anexemplary, high-level overview process 100 of one embodiment of thepresent disclosure. As will be understood and appreciated, theexemplary, high-level overview process 100 shown in FIG. 1 representsmerely one approach or embodiment of the present systems and methods.The various exemplary processes discussed in FIGS. 1-4 will further bediscussed in association with FIGS. 5-8 . The current disclosureprovides a process (and system) for converting waste materials (e.g.,coal, carpet scraps, wood, lump coal, weeds, and the plastic parts ofcell phones) into hydrocarbon fuels and fertilizer. The exemplaryprocess 100 includes: a bacterial and/or enzymatic pre-digestion process200; a storage and purification of naphtha vapors process 300; and aconversion of hydrocarbon by-products to fertilizer process 400. Invarious embodiments, process 200 generally may produce solidhydrocarbons and activated coal slurry. In some embodiments, process 300may include the production of naphtha vapors via a catalytic reductionprocess which may be condensed, dewatered, and stored and/or purified.In some embodiments, process 400 may include converting hydrocarbonby-products into fertilizer, or other uses. Each of these processes willbe discussed in turn.

Turning now to FIG. 2 , a flowchart of a pre-digestion process 200 isshown in accordance to one embodiment of the present disclosure. Thesystem begins at step 202, which includes mixing of raw materials, suchas a slurry of coal fines, with water. In various embodiments, at step206, the raw material mixture is introduced into a holding tank. In atleast one embodiment, the raw material and water is mixed directly inthe holding tank.

In some embodiments, the process continues at step 210, which includesadding a proprietary culture of bacteria, urea (or amines), anddispersant to the holding tank. This disclosure places no limitations onthe type of bacteria (e.g., Bacillus Firmus) and dispersant agent (e.g.,dawn or ivory soap) used. In various embodiments, the mixture may have apH ranging from 7-9. In at least one embodiment, there is no externalheating or cooling, and the process runs at ambient temperature andpressure. Further, in some embodiments, the mixture breaks down (e.g.,“loosens”) the hydrocarbons without agitation or further mixing(although in some embodiments, the mixture may be stirred at suitableintervals).

In various embodiments, at step 214, the bacterial culture multipliesand may produce a variety of enzymes (e.g. lipase), which attack thecoal particles, dissolving and extracting some of the hydrocarbons whileconverting others to shorter chain hydrocarbons, proteins, or alcohols.In some embodiments, after an appropriate time interval, the bacteriaand enzymes may extract some hydrocarbons, split others to shorter chainhydrocarbons, proteins or alcohols and generally weaken and deterioratethe structure of the coal fines, making it possible for furtherseparation of the hydrocarbons from the remaining rock/mineral matrix ofthe coal. As will be understood from discussions herein, the timeinterval may be any suitable time interval such as one day, two days,one week, one month, etc.

After step 214, the “pre-digested” hydrocarbon mixture is furtherprocessed to produce naphtha vapors and fertilizer, as further discussedherein.

Turning now to FIG. 3 , a flowchart of a storage and purification ofnaphtha vapors process 300 is shown in accordance with one embodiment ofthe present disclosure. Beginning with step 302, the system receives acoal slurry mixture (e.g. pre-digested mixture from FIG. 2 ) in a surgetank. In at least one embodiment, any free water is drawn off of themixture for removal and urea is added and mixed into the contents.

At step 304, the coal slurry is pumped and/or drained into a vacuumdigester where hydrocarbons are further converted to shorter chainhydrocarbons, proteins, and/or alcohols, and water is separated.

At step 306, by way of catalytic reduction, the lighter components fromthe coal slurry are removed producing naphtha vapors.

Continuing with the present process, at step 308, the naphtha vapors arecondensed, producing various liquids including a liquid hydrocarbonmixture.

At step, 310, the liquid hydrocarbon mixture may be purified by a seriesof compressors and tanks.

FIG. 4 depicts a flowchart of an exemplary process 400 for convertinghydrocarbons to naphtha vapors and fertilizer, according to oneembodiment of the present disclosure.

The process begins at step 402, where a digester tank receives andprocesses the hydrocarbon mixture, such as a coal slurry mixture fromthe process associated with FIG. 2 or combustion gases from the processof FIG. 3 . At step 406, the hydrocarbon mixture is vaporized intolighter naphtha vapors. The process continues at step 410, where thenaphtha vapors are condensed and separated and transported to either anaphtha pump or kerosene pump and stored.

As will be understood, the digester tank at step 402 may not vaporizeall of the gases produced from the hydrocarbon mixture and any remainingcombustion gases are further processed. In various embodiments, thecombustion gases are treated in an exhaust accumulator tank at step 414.

At step 416, a series of scrubber tanks purify and clean the combustiongases and produce water loaded with electrolytes. At step 420, the waterloaded with electrolytes along with creosote, a carbonaceous materialformed during process 300, may be stored in chemical tote bins. At step424, an additional amount of urea, a dispersant agent, and a proprietaryof bacteria culture is added to the chemical tote bins.

At step 428, a fertilizer solution is produced. In various embodiments,the production of the fertilizer solution at step 428 is initiated bythe reaction of bacterial enzymes and scrubber water with creosotestream, further details of which will be discussed in association withdescription of FIGS. 7 and 8 .

FIGS. 5-8 show exemplary components of the system discussed herein.Further, FIGS. 5-8 and discussions related thereto may help explain howexemplary processes discussed herein are completed via various systemcomponents.

Turning now to FIG. 5 , which shows various exemplary components of thesystem used to complete the processes described herein. In the exemplaryembodiment shown in FIG. 5 , the system 500 includes: an enzymaticpre-digestion tank 506, a surge day tank 520, a tank 518, vacuumdigester 530, a column 548, a condenser 556, a separator tank 560, aknockout pot 564, a gas compressor 572, and propane tanks 574, 578.

Generally, tank 506 is for preparing a working mixture (process 502) andis connected to tank 520 for further biodegradation (process 510) and apump 526. In some embodiments, tank 520 is connected to vacuum digester530 which is used for the collection of viscous substances 512, 508, and528 via pump 526 (process 522). In some embodiments, vacuum digester 530is connected to a heating reservoir 532 and a U-shaped pipe 536 forcollecting combustion gases 538, overflow products 540, and creosote542. In various embodiments, the vacuum digester 530 is connected tocolumn 548 for separating lighter components from heavier componentsallowing the vaporized mixture to pass through condensers 556 andseparator tank 560 which separates droplets of liquid having lower vaporpressure (process 554). In further embodiments, separator tank 560 isconnected to a knockpot 564 and gas compressor 572 for the separation ofvapors into individual components such as natural gas and propane 574,578 (process 570).

In various embodiments, at process 502, a combination of slurry coalfines, water, and a proprietary culture of bacteria is introduced to theenzymatic pre-digestion holding tank 506, for breaking down thehydrocarbon-containing materials for further processing. In variousembodiments, the holding tank 506 may be of any suitable size andconstructed from any suitable material. In particular embodiments, theholding tank 506 may have a 500 bbls capacity, constructed fromfiberglass, and may be enclosed with a roof.

In some embodiments, any suitable amount of urea (or amines) and adispersant agent (e.g. dawn or ivory soap) may be added to promotemixing without agitation. Generally, the mixture will achieve a pHranging from 7-9. In various embodiments, there is no external heatingor cooling necessary, and the process may run at any suitable ambienttemperature and pressure.

In various embodiments, the biodegradation of the coal fines may beinitiated by any suitable bacteria (e.g. Bacillus Firmus, etc.). In someembodiments, the mixture added to the coal fines may include bacteria,about 0.66% of urea by weight (e.g., at least one embodiment, with dailyurea treatments), about 3-6% of liquid dishwasher soap (e.g. Dawn® orIvory®) as an emulsifier, and about 150 mL-300 mL of 15-15-15 plantfertilizer (e.g., Miracle-Gro® or similar fertilizer with 15% nitrogen,15% phosphorus, and 15% potassium by weight). In at least oneembodiment, the mixture may be blended 50/50 with any suitable crude oiland/or engine oil. In some embodiments, during the pre-digestion of thecoal fines, the bacterial culture multiplies and may produce a varietyof enzymes (e.g. extra cellular lipase, etc.).

In particular embodiments, Bacillus Firmus bacterial biomass is suppliedto tank 506 to facilitate the biodegradation process in the amount of0.2 wt. % with the number of colony forming units (CFU) equal to5.07×10⁵ per one gram of the biomass. Generally, in 24 to 48 hours, theCFU number increases to amount 8.15×10⁹ per one gram of the biomass. Insome embodiments, the bacteria may begin to synthesize exoenzymes oflipase, these enzymes may attack the coal particles and dissolve andextract some of the hydrocarbons while converting others. In variousembodiments, after a suitable time interval, the bacteria and enzymesmay extract some hydrocarbons, split others, and generally weaken anddeteriorate the structure of the coal fines, making it possible for thevacuum digester 530 to separate the hydrocarbons from the remainingrock/mineral matrix of the coal.

In some embodiments, at process 510, the hydrocarbon and activated coalslurry 508 (from process 502) is pumped to a day tank 520. In someembodiments, any suitable amount of urea (e.g. 1-3 lbs) and water (e.g.30-60 gal) is additionally added to tank 520. In various embodiments,coal fines, wood chips, and/or recycled carpet 512 may be placed intotank 518 and mixed with any suitable amount of urea (e.g. 1-3 lbs) andwater (e.g. 30-60 gal). In various embodiments, tanks 520 and 518 may beof any suitable size and constructed from any suitable materials.

In various embodiments, at process 522, the activated coal slurry 508 ispumped/drained 526 to the vacuum digester 530 from the day tank 520. Insome embodiments, materials 512 from tank 518 may be pumped/drained 526to the vacuum digester 530. In one embodiment, carbonaceous materials(e.g., coal slurry 508, coal fines, wood chips, and/or recycled carpet512, and/or cell phones (or portions thereof 528) are fed into thevacuum digester 530, which may contain an enclosed vessel fitted with aU-shaped diesel-fired burner lance 536.

In particular embodiments, this U-shaped tubular system within thedigester 530 allows the movement of the carbonaceous materials andduring this transit movement, the gasified product vapors are extractedunder a constant vacuum. In some embodiments, a burner 532 is used toindirectly heat the carbonaceous materials and may not come into directcontact with the materials. In one embodiment, other solid feedstockssuch as wood, lump coal, chopped carpet fibers, plastic bottles, weedsand cell phones 528 can be charged for reduction and consumption in thevacuum digester 520. In various embodiments, carbonaceous materials(508, 512, 528) are further converted to hydrocarbon fuel with theaddition of urea and water. In some embodiments, the larger materialssettle onto a support grid 534 located just above the firetube assembly.In further embodiments, various types of combustion gases (e.g. CO₂, CO,NOX, etc.) 538 may be produced and captured from the diesel-fueledburner lance 536.

Continuing with process 522, lighter components are liberated fromcarbonaceous materials and other feedstock (508, 512, 528) and may risethrough any suitable column apparatus or apparatuses 548. In variousembodiments, as the temperature inside the vacuum digester 530 rises,heavier hydrocarbons are liberated and may condense at double-pipe heatexchangers (not shown) and lighter components may rise through thecolumn 548. In some embodiments, catalytic reduction may occur in vacuumdigester 530. In some embodiments, via catalytic reduction, naphthavapors 544 may be produced and may also rise through the column 548. Inparticular embodiments, column 548 may be packed with Raschig rings ofany suitable dimension (e.g. 1 inch) and any suitable material (e.g.aluminum).

In some embodiments, a pipe line (not shown) extends from column 548allowing naphtha vapors 544 and other vapors to proceed for furtherprocessing. In various embodiments, the pipeline extending from thecolumn 548 may be of any suitable dimension (e.g. 2 inches) andconstructed from any suitable materials. From the bottom of the vacuumdigester 530, a drain 542, in various embodiments, removes creosote,while another drain 540 may be used to drain water, amines andcarbonates.

In various embodiments, at process 554, the liberated naphtha vapors 544may exit packed column 548 and proceed to a series of double-pipewater-cooled heat exchangers (not shown), where some components maycondense and fall into a vertical tank 560. In various embodiments, anysuitable condenser(s) and vertical tank apparatuses may be used for thisprocess. In some embodiments, liquid products captured may includewater, amines, olefin hydrocarbons, paraffinic hydrocarbons, possiblyalcohols and ketones. As will be understood, when coal is dissolved, awide variety of hydrocarbon products result.

In some embodiments, vapors that are too light to be efficientlycondensed with a cooling water service (e.g., at the double-pipewater-cooled heat exchangers), may proceed through a knockout pot 564(final liquid trap) to reach a gas compressor 572, a motor drivenpositive-displacement unit. In various embodiments, any suitableknockout pot apparatus may be used for this process. In furtherembodiments, any suitable gas compressor apparatus that may reach anysuitable ambient atmospheric pressure (e.g. 125 psig discharge) may beused for this process. In various embodiments, the compressed vapors maygo to storage bullet tanks 574 and 578.

In some embodiments, there is manual drainage from the knockout pot 564and “floating mud” (e.g. lithium cobalt, copper, nickel compounds) arestored in a settling tank with a skimmer 568.

In various embodiments, the gas compressor 572 is strong enough to pulla vacuum (about 18 Hg) back to the vacuum digester 530, and generallypulls the naphtha vapors forward through the double-pipe heat exchangersand the receiver/knockout pot 564. In some embodiments (not shown), thesystem includes a saturates gas plant, to clean and separate the vaporsinto individual components such as natural gas and propane (which mayalso be stored in tanks 574 and 578).

FIG. 6 depicts additional system components, according to one embodimentof the present disclosure. In the exemplary embodiment shown in FIG. 6 ,the system includes: an atmospheric digester lance 604, an atmosphericdigester 606, column 618, condensers 628, separator tank 630, kerosenepump 636 and naphtha pump 640. Generally, the atmospheric digester 606is connected column 618 for the purification of vapors (process 604). Insome embodiments, column 618 is connected to condensers 628 and aseparator tank 630 where vapors are further separated by either akerosene pump 636 or naphtha pump 640 (process 624).

In various embodiments, at process 604, combustion gases from thediesel-fueled burner lance 604 may be captured. Continuing with process604, combustion gases 538, diesel fuel 602 may accumulate into theatmospheric digester 606. From the bottom of the atmospheric digester606, multiple drains, in various embodiments, remove creosote 610, whileanother drain 614 may be used to drain water, amines, and carbonates. Insome embodiments, the mixture of gases are evaporated allowing lighternaphtha vapors 620 and/or lighter components to be liberated and risethrough to any suitable packed column apparatus 618. In at least oneembodiment, combustion gases 645 may be captured and transported to ascrubber system discussed herein.

At process 624, in particular embodiments, the naphtha vapors 620 fromthe packed column 618 proceed to a series of double-pipe water-cooledheat exchangers 628, where some components condense and travel into aseparator tank 630. In various embodiments, any suitable separator tank(e.g. vertical or horizontal orientation) constructed from any suitablematerial with a wide ranging pressure requirements may be used for thisprocess. In some embodiments, separator tank 630 may be fitted with astrainer (not shown) that filters content that may arrive and/or departthe tank. In one embodiment, separation and/or filtering of the contentmay be based on density, force, temperature, direction, velocity and/orpressure. In various embodiments, tank 630 is connected to kerosene pump636 and naphtha pump 640 which may further separate naphtha vapors fromkerosene. The naphtha vapors and/or kerosene may then be stored insuitable tanks.

FIG. 7 shows exemplary system components, including: an exhaustaccumulator tank 704, ejectors (712, 716), scrubber tanks (722, 726),scrubber recycle drum 734, scrubber recycle pump 738 and internalcombustion engine 742. Generally, the exhaust accumulator tank 704(process 706) is connected to ejectors 712, 716, which are used to pumpgases and/or vapors to scrubber tanks 722, 726 (process 710). In someembodiments, scrubber tanks 722, 726, produce water loaded withelectrolytes and are connected to scrubber recycle drum 734, scrubberrecycle pump 738, and internal combustion engine 742 (process 730).

In various embodiments, at process 706, the system captures thecombustion exhaust gases (538, 540) and treats them with CO₂ produced bythe burning of diesel at the rate of 5 gal/hr, water that may beprovided the scrubber tanks (722, 726) and any unburned hydrocarbons oremissions that may be pulled by vacuum to the exhaust accumulator tank704. In various embodiments, the scrubber tanks (722,726) may roughly be3,000-7,000 gal in capacity and sealed. At process 710, the compoundsfrom exhaust accumulator tank 704 are transported to ejectors (712,716). In some embodiments, exhaust gases from ejectors (712, 716) aretransported to a pair of scrubber tanks (722, 726), filled with waterand amines. In various embodiments, any suitable scrubber tank (e.g.venture, orifice, spray tower, cyclonic spray tower, dynamic, traytower, etc.) may be used for this process.

In at least one embodiment, tank 722 is fitted with an electric grid720. In various embodiments, the design of the electric grid 720includes a series of PVC pipes spaced about 1 to 2 inches apart and anysuitable wire constructed from any suitable material (e.g. cooper). Inparticular embodiments, copper wire may be wrapped around the PVC pipein any suitable orientation allowing water to circulate around eachindividual wire. In some embodiments, the electric grid 720 provides anelectric field to encourage the reduction of hydrogen gas into an activeionized species, which will react to drive the carbonate and aminereactions. In some embodiments, the exhaust gases react with theamine-water solution and produce urea and/or ammonia, while the CO₂turns into carbonate species in the water. In some embodiments, thescrubber system may produce some hydrogen and methane, which are used tohelp fuel the gasoline engine, which may drive the scrubber pump 738. Inat least one embodiment, at higher loadings, the scrubber producesnearly enough hydrogen and methane to displace the gasoline and fuel theengine 742 completely on scrubber gas. In a particular embodiment, atrace amount of gasoline remains in the manifold to power the engine.

In various embodiments, scrubber water overflows into a surge tank 726,where it feeds the scrubber pump 728. In at least one embodiment, thesystem includes a scrubber recycle pump 734 that drives two ejectorventuri (712,716) to help facilitate the removal of particulate matter,which then creates a vacuum to pull the exhaust vapors to theaccumulator vessel 704. In various embodiments, the system recirculatesscrubbing liquid in order to decrease the solid content of the scrubbingliquid. In some embodiments, the scrubber water eventually accumulateselectrolytes, which can saturate and precipitate in the scrubber,impacting its operation. Therefore, before the scrubber water reachessaturation, in at least one embodiment, the scrubber may be dumped andthe accumulated electrolytes may be used in the creosote conversionprocess (discussed herein).

FIG. 8 shows an exemplary chemical tote 804, which will be described inconjunction with process 802. In various embodiments, at process 802,scrubber water loaded with electrolytes from tanks 722, 726 along withcreosote (542, 610) is converted into fertilizer. In some embodiments,the creosote stream from the digester is stored in any suitable chemicaltote bin 804. In particular embodiments, the chemical tote bin 804 maybe a four-foot-cubical polypropylene tank with a threaded top lid and abottom valve.

In various embodiments, creosote (542, 610) is mixed with water from thescrubber tanks (722, 726), urea, dispersant and a bacteria culture (e.g.Bacillus Firmus). In some embodiments, the bacterial enzymes andscrubber water react with the creosote stream to create a thickfertilizer solution, rich in nitrates, carbonates, and mineralnutrients. In various embodiments, the mixture may have five to tengallons a day drained from the bottom valve and returned through the toplid, in effect a stirring/mixing procedure. In some embodiments, thebatch is turned once or twice a day for one to two weeks, occasionallyadding more urea as needed. In particular embodiments, after about twoweeks, the urea stops making nitrates and starts making ammonia, whichammonia odor is a signal that conversion is complete and the fertilizeris ready to sell.

While various aspects have been described, additional aspects, features,and methodologies of the claimed disclosure will be readily discerniblefrom the description herein, by those of ordinary skill in the art. Manyembodiments and adaptations of the disclosure and claimed embodimentsother than those herein described, as well as many variations,modifications, and equivalent arrangements and methodologies, will beapparent from or reasonably suggested by the disclosure and theforegoing description thereof, without departing from the substance orscope of the claims. Furthermore, any sequence(s) and/or temporal orderof steps of various processes described and claimed herein are thoseconsidered to be the best mode contemplated for carrying out the claimeddisclosure. It should also be understood that, although steps of variousprocesses may be shown and described as being in a preferred sequence ortemporal order, the steps of any such processes are not limited to beingcarried out in any particular sequence or order, absent a specificindication of such to achieve a particular intended result. In mostcases, the steps of such processes may be carried out in a variety ofdifferent sequences and orders, while still falling within the scope ofthe claimed disclosure. In addition, some steps may be carried outsimultaneously, contemporaneously, or in synchronization with othersteps.

The embodiments were chosen and described in order to explain theprinciples of the claimed disclosure and their practical application soas to enable others skilled in the art to utilize the inventions andvarious embodiments and with various modifications as are suited to theparticular use contemplated. Alternative embodiments will becomeapparent to those skilled in the art to which the claimed disclosurepertain without departing from their spirit and scope. Accordingly, thescope of the claimed disclosure is defined by the appended claims ratherthan the foregoing description and the exemplary embodiments describedtherein.

What is claimed is:
 1. A method for transforming waste into hydrocarbonfuels comprising: creating a predigested coal slurry by mixing coalfines, water, urea, a culture of Bacillus firmus bacteria and adispersant agent in a pre-digestion tank; transferring the predigestedcoal slurry to a digester, including a first burner lance; heating thepredigested coal slurry via the first burner lance, producing combustiongases and first naphtha vapors; and condensing and storing the firstnaphtha vapors.
 2. The method of claim 1, wherein the digester is afirst digester, the method further comprising: heating the combustiongases via a second burner lance in a second digester, producing secondnaphtha vapors; and condensing and storing the second naphtha vapors. 3.The method of claim 2, wherein: heating the predigested coal slurryfurther produces first creosote solids; and the method further comprisestransporting the first creosote solids to a chemical tote bin.
 4. Themethod of claim 3, wherein the method further comprises creating acreosote mixture by mixing the first creosote solids with water,bacteria, and urea.
 5. The method of claim 4, wherein the method furthercomprises stirring the creosote mixture at regular intervals for atleast a week to produce fertilizer.
 6. The method of claim 5, wherein:the combustion gases are first combustion gases; and heating the firstcombustion gases via the second burner lance produces second combustiongases; and the method further comprises transporting the secondcombustion gases to at least one scrubber tank for scrubbing the secondcombustion gases.
 7. The method of claim 6, wherein: the at least onescrubber tank produces scrubber water comprising electrolytes; and themethod further comprises adding the scrubber water to the creosotemixture.
 8. The method of claim 7, wherein the at least one scrubbertank is operatively connected to at least one ejector for scrubbing thesecond combustion gases.
 9. The method of claim 1, wherein thedispersant agent is liquid dish soap or a chemical equivalent thereof.10. The method of claim 1, wherein the predigested coal slurry has a pHof about 7-9.
 11. The method of claim 1, wherein the predigested coalslurry includes about 0.66% by weight urea.
 12. A method of claim 1,wherein the dispersant agent comprises liquid dish soap in aconcentration range of about 3-6% by weight of the predigested coalslurry.
 13. The method of claim 1, wherein the predigested coal slurryfurther includes about 150-300 ml of 15-15-15 plant fertilizer.
 14. Themethod of claim 13, wherein the method further comprise transferring thepredigested coal slurry to a day tank.
 15. The method of claim 14,wherein the method further comprises adding one or more of a groupcomprising coal fines, wood chips, and recycled carpet, to thepredigested coal slurry in the day tank.
 16. The method of claim 15,wherein the method further comprises adding 1-3 lbs of urea and 30-60gallons of water to the predigested coal slurry in the day tank.
 17. Themethod of claim 16, wherein the method further comprises pumping ordraining the predigested coal slurry from the day tank to the digester.18. A system for transforming waste into hydrocarbon fuels comprising: apre-digestion tank configured to create a predigested coal slurry bymixing coal fines, water, urea, a culture of Bacillus Firmus bacteriaand a dispersant agent; a digester operatively connected to thepre-digestion tank and comprising a first burner lance, the digesterconfigured to heat the predigested coal slurry via the first burnerlance, producing combustion gases and first naphtha vapors; adouble-pipe heat exchanger fluidly connected to the digester, thedouble-pipe heat exchanger configured to condense the first naphthavapors; a first naphtha tank fluidly connected to the double-pipe heatexchanger, the first naphtha tank configured to store the condensedfirst naphtha vapors; and a chemical tote bin configured to receivecreosote solids produced by the digester, water, bacteria, and urea tothereby create a creosote mixture.
 19. The system of claim 18, whereinthe digester is a first digester, the system further comprising: asecond burner lance in a second digester fluidly connected to the firstdigester, the second burner lance configured to produce second naphthavapors from the combustion gases; a condenser fluidly connected to thesecond digester, the condenser configured to condense the second naphthavapors; and a second naphtha tank configured to store the condensedsecond naphtha vapors.
 20. The system of claim 19, wherein: the systemfurther comprises: at least one scrubber tank for scrubbing thecombustion gases; and at least one column operatively connected to thesecond digester for transporting the second naphtha vapors to thecondenser; the at least one scrubber tank is operatively connected to atleast one ejector for scrubbing second combustion gases produced by thesecond burner lance; and the pre-digestion tank is about 500 bblscapacity and comprises fiberglass.